Bag turning device

ABSTRACT

An inverting cone mounted to an expansion box for turning a bag assembly having an assembly opening, an assembly extended length, and an assembly width. The inverting cone has an inlet separated from an outlet by a length The inverting cone inlet is smaller than the assembly opening of the bag assembly, the inverting cone length is longer than the extended length of the bag assembly, and the cross-sectional area of the inverting cone increases from the inlet to the outlet along the length of the inverting cone. The expansion box has an expansion chamber separated from a manifold chamber by a baffle plate, and the baffle plate includes concentric circles of apertures communicating between the expansion chamber and the manifold chamber. The outlet of the inverting cone is open to the expansion chamber opposite to the center of the concentric circles of apertures in the baffle plate, and the side walls of the expansion box as spaced further apart than the assembly width of the bag assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a divisional of pending U.S. patentapplication Ser. No. 10/126,644, filed on Apr. 19, 2002, which is acontinuation of U.S. patent application Ser. No. 60/285,565, filed onApr. 20, 2001. These references are all hereby incorporated herein intheir entirety by specific reference thereto.

BACKGROUND

[0002] Bag assemblies, such as air bags, are typically formed ofmultiple component parts. However, the process of forming the bagassemblies requires much manual work. Therefore, there is a need formethods and apparatuses that can reduce the manual work required informing a bag assembly from multiple components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The present invention can be better understood with reference tothe Detailed Description below in combination with the followingDrawings:

[0004]FIG. 1A is a perspective view of one embodiment of a bag assemblyformed by the present invention.

[0005]FIG. 1B is a perspective view of another embodiment of a bagassembly formed by the present invention.

[0006]FIG. 2 is a diagram illustrating a laser cutting table.

[0007]FIG. 3A is a diagram illustrating a 3-way transfer device.

[0008]FIG. 3B is a cross-sectional view illustrating an acceleratorpick-up device for use as one embodiment of a pick-up device in the3-way transfer device of FIG. 3A.

[0009]FIG. 4A is a perspective view illustrating a loading stationplatform.

[0010]FIG. 4B is a cross-sectional view of the loading station platformfrom FIG. 4A, with component parts therein.

[0011]FIG. 5A is a perspective view illustrating a sewing frame.

[0012]FIG. 5B is a diagram illustrating the frame from FIG. 5A at alayer detector and a sewing and cutting area.

[0013]FIG. 6 is a diagram illustrating a diagram illustrating a circularsewing device.

[0014]FIG. 7A is a diagram illustrating a turning device of the presentinvention.

[0015]FIG. 7B is a cross-sectional view of the turning device of FIG.7A, illustrating the passage of a bag assembly therethrough.

[0016]FIG. 8 is a diagram illustrating a metal detector.

DETAILED DESCRIPTION

[0017] Referring now to the figures, and in particular to FIGS. 1A and1B, there is show a bag assembly 30 formed of component parts 20.

[0018] In one embodiment of the present invention, the component parts20 are formed on a laser cutting table 210, as illustrated in FIG. 2.The laser cutting table 210 includes a conveyor belt 211, a laser 212,and a laser carriage 213. Layer(s) of fabric and/or plastic film 10 arerolled onto the conveyor belt 211. The laser 212 is used to cut thefabric and/or plastic film 10. The conveyor belt 211 moves the fabricand/or plastic film 10 in a X_(C) direction under the laser 212, and thelaser 212 is mounted on a carriage 213 that moves the laser 212 in aY_(C) direction. The movement of the conveyor belt 211 and the lasercarriage 213 are coordinated to cut the various component parts 20 outof the layers of fabric and/or plastic film 10.

[0019] The cut component parts 20 are separated from the remnant fabricand/or plastic film 10, and are positioned to be picked up for transferand consolidation into like groups of component parts 20. The pickup,transfer, and consolidation can be done by a robot, a 3-way transferdevice, or other devices or methods. Movements of the robot, 3-waytransfer device, or other device or method, can be coordinated toperform the pickup, transfer, and consolidation by a computer or otherelectronic controller.

[0020] A 3-way transfer device 320 is illustrated in FIGS. 3A and 3Bthat can be used in the present invention. The 3-way transfer device 320includes an X-platform 321 and an Y-Z carriage 322. The X-platform 322is a moveable table or belt that provides movement in the X_(T)direction. The Y-Z carriage 322 includes a carriage guide 323, atransfer carriage 324, a lifting device 325, and a pick-up device 330.The carriage guide 323 extends over the X-platform 321 in the Y_(T)direction, which is perpendicular to the X_(T) direction of theX-platform 321. The transfer carriage 324 moves in the Y_(T) directionalong the carriage guide 323. The lifting device 325 is mounted to thecarriage guide 324 and has the pick-up device 330 mounted to an end ofthe lifting device 325. The lifting device 325 moves the pick-up device330 up and down in the Z_(T) direction, which is perpendicular to theX_(T) direction and the Y_(T) direction.

[0021] The pick-up device 330 is adapted to secure one or more of theparticular component part(s) 20 for movement of the particular componentpart(s) 20. In one embodiment, the pick-up device 330 is an acceleratorpick-up device which uses pneumatic pressure to secure the componentpart(s) 20, such as a coval device. The accelerator pick-up device 330of the present invention includes a venturi 331, an air supply tube 334,and a screen 336. The air supply tube 334 is positioned inside theventuri 331 with the supply tube exit 335 directed towards the smallerdiameter 332 of the venturi 331. Pressurized air is directed through theair supply tube 334 and exits toward the small diameter 332 of theventuri 331. The speed of the pressurized air through the venturi 331lowers the pressure at the small end 332 of the venturi 331. The lowpressure at the small end 332 of the venturi 331 amplifies a vacuum atthe larger open end 333 of the venturi 331. The amplified vacuum at thelarger open end 333 of the venturi 331 is used to secure the particularcomponent part(s) 20. Accelerator pick-up devices, such as the covaldevice, are typically used to secure rigid articles. Flexible articles,such as the component parts 20 of the present invention formed fromfabric and/or plastic film 10, can be drawn into the venturi 331 of anaccelerator pick-up device 330. To prevent drawing the particularcomponent part(s) 20 into the venturi 331, the screen 336 is positionedover the larger open end 333 of the venturi 334. The accelerator pick-updevice has the advantage that only pressurized air is necessary tooperate the pick-up device. Although the present invention has beenexplained with the use to an accelerator pick-up device as the pick-updevice 330, it is contemplated by the present invention that otherpick-up devices that are capable of securing one and/or more componentparts 20 can be used in place of the accelerator pick-up device 330 asdescribed herein.

[0022] Component parts 20 are consolidated into loading stationplatforms, such as the loading station platforms 400 in FIGS. 4A and 4B.The component parts 20 can be loaded directly into the loading stationplatforms 400, or can be placed in a staging area prior to loading intothe loading station platforms 400. Each loading station platform 400holds a series of a particular component part 20. The particularcomponent parts 20 at each station 400 must all be aligned in the sameorientation. To keep the component parts 20 aligned, the loading stationplatforms 400 can have recesses 410 with side walls 411 that contourwith the silhouette of the component part 20. A self adjusting lift 420of the loading station platforms 400 positions the series of componentparts 20 with the top component part 20 always at the same selectedheight. In this manner, the component parts 20 at each different station400 will have the same height, allowing the loading station platform 400to position a different station of component parts 20 at standard heightand location for pick up. In one embodiment, the loading stationplatform 400 can also be the X-movement platform of a 3-way transferdevice, such as the 3-way transfer device 220 illustrated in FIGS. 2Aand 2B. In another embodiment, the loading station platform can merelybe a presentation table or a part of another component in the process offorming the component parts 20.

[0023] The component parts 20 from the loading station platforms 400 areplaced into a sewing frame, such as the sewing frame 510 illustrated inFIGS. 5A and 5B. The sewing frames 510 have a top frame member 511 and abottom frame member 512. The sewing frames 510 are designed to combineparticular component parts 20, and different combination of componentparts 20 can be combined with different sewing frames 510. The sewingframes 510 also include frame indicators 513 that indicate whichcomponent parts 20 the sewing frame 510 will assemble. The bottom framemember 512 rests on a table 520 with frame sensors 521 that detect theframe indicators 513 to insure that the correct sewing frame 510 will beused to assemble the desired combination of component parts 20. Thecomponent parts 20 have tabs 21 which are detected through the sewingframe 510 by component sensors 522 in the table 520. The sensors 521 and522 detect both if the correct component parts 20 have been loaded inthe frame, and if the particular component parts 20 are correctlypositioned in the frame 510. After the component parts 20 have beenpositioned in the bottom frame member 512, the top frame member 511 ispositioned on the bottom frame member 512, and the two frame members 511and 512 are secured together holding the component parts 20 in position.In one embodiment, the top frame member 511 and the bottom frame member512 are secured together by a force device such as electromagnets or thelike.

[0024] The secured sewing frame 510 and component part(s) 20 are movedto a layer detector 530, and then to a sewing and cutting area 540, suchas illustrated in FIG. 5B. The layer detector 530 insures that thecorrect number of layers of component parts 20 are present in the sewingframe 510. In the sewing and cutting area 540, an automated sewingmachine 541 sews the component parts 20 together an assembly 30. If theassembly 30 requires additional component parts 20, the frame 510 can bepositioned at a second station for removing a frame member 511 or 512,loading the additional component parts 20, and securing frame top andbottom frame members 511 and 512 together, which is then moved throughthe layer detector 530 to detect if the proper amount of layers arepresent, and then to the sewing and cutting area 540 where thecomponents 20 are sewn together. Once the assembly 30 is complete, frame510 and assembly 30, and the top frame member 511 is removed and theassembly 30 is removed from the bottom frame member 512.

[0025] For the construction of certain circular air bags, such ascircular air bags used in the steering wheel of the driver's side of anautomobile, the assembly 30 must also include an additional componentpart or parts 20 a which is added at a circular sewing device, such asthe circular sewing device 600 illustrated in FIG. 6. The circularsewing device 600 includes a spindle 610, a spindle cover 620, a sewinghead 630, an edge detector 640, and a layer detector 640. The componentparts 20 sewn together in the frame 510 are transferred to the spindle610 with the additional component part(s) 20 a. The sewn togethercomponent parts 20 and the additional component part(s) 20 can betransferred to the spindle 610 by a robot, 3-way transfer device, orother device or method. In one embodiment, the same transfer device isused that was used to transfer parts to the frame member 510. Thespindle cover 620 presses down on the component parts 20 to secure thecomponent parts 20 to the spindle 610. The edge detector 630 has aninside sensor 631 and an outside sensor 632. As the component parts 20are rotated on the spindle 610, the edge detector 630 checks foralignment of the various component parts 20 on the spindle 610 byrequiring those parts to always cover the inside sensor 631, and nevercover the outside sensor 632. Also, as the spindle 610 rotates, thelayer detector 640 monitors the component parts 20 to insure that thecorrect number of component parts 20 are present on the spindle 610, andthat none of the layers of the component parts 20 are folded over. Thecomponent parts 20 are rotated on the spindle 610 while the sewing head630 sews the component parts 20 together at the periphery to form theassembly 30. Once the sewing head 640 has completed the sewingoperation, the spindle cover 630 is removed to allow access to theassembly 30.

[0026] The stitches sewn into the component parts 20 can be inspected byan artificial vision checking system to determine if the stitches matchthe appearance of the stitches in a pre-selected pattern. The artificialvision checking system can perform the check after all of the stitcheshave been made in the component parts 20 to form the assembly 30, orduring the process of sewing perform a check on the stitches that havebeen formed in the component parts 20.

[0027] The assemblies 30 formed above typically must be turnedinside-out to form an air bag with the free ends of the component parts20 disposed inside of the air bag. A turning device can be used to turnthe assemblies 30 inside-out, such as the turning device 700 illustratedin FIGS. 7A and 7B. The assemblies 30 can be transferred to the turningdevice 700 by a robot, 3-way transfer device, or other device or method.

[0028] The turning device 700 generally includes a positioning arm 710,an inverting cone 720, an expansion box 730, and ejection jets 740. Thepositioning arm 710 is an arm that extends laterally to position the airbag 30 over the inverting cone 720. The positioning arm 710 can actuatewith pneumatics, electronics, or any suitable method of causing linearmotion.

[0029] The inverting cone 720 has an inlet 721 smaller than the opening31 in the newly formed bag assembly 30. The cross sectional area of theinverting cone 740 increases along the length 722 of the inverting cone740 to an outlet 723. The length 722 of the inverting cone 720 isslightly longer than the stretched out length of the formed bag assembly30. In this manner, the bag assembly 30 will be fully turned inside tooutside before the bag assembly exits the inverting cone 720, asexplained below. The outlet 723 of the inverting cone 720 is centered inthe top of the expansion box 730.

[0030] The expansion box 730 has an expansion chamber 731 and a manifoldchamber 732 separated by a baffle plate 733. The expansion chamber 731forms the top portion of the expansion box 730, and the manifold chamber732 forms the bottom of the expansion box 730. The baffle plate 733forms the bottom of the expansion chamber 731 and the top of themanifold chamber 732. Apertures 734 in the baffle plate 733 communicatebetween the expansion chamber 731 and the manifold chamber 732. Theapertures 734 in the baffle plate 733 are positioned in a pattern ofconcentric circles 735. The aperture area of each concentric circle 735is larger than the aperture area of the concentric circle 735immediately inside that particular concentric circle 735. The outlet 723of the inverting cone 720 is located in the top of the expansion box730, is open to the expansion chamber 731, and is positioned opposite tothe center of the concentric circles 735 of apertures 734 in the baffleplate 733. The expansion box 730 is positioned horizontally with theside walls of the expansion box 730 being separated sufficiently toaccommodate the expanded flat bag 30. One side wall of the expansionchamber 730 is an exit door 736 leading from the expansion chamber 731to an exit ramp 737.

[0031] The ejection jets 740 are located in the lower portion of theinverting cone 720, or top portion of the expansion chamber 731. Theejection jets 740 are positioned to direct air downward toward thebaffle plate 733 and in the direction of the exit door 736 in theexpansion box 730.

[0032] In operation, the positioning arm 710 locates the bag assembly 30over the inlet 721 of the inverting cone 720 such that the inlet 721 isaligned within an opening 31 in the bag assembly 30. A vacuum is thenapplied to the manifold chamber 732 of the expansion box 730, creating avacuum in the expansion chamber 731 and the inverting cone 720. Thevacuum in the inversion cone 720 draws the material of the bag assembly30 through the opening 31 in the bag assembly 30 and down the invertingcone 720. After all of the material of the bag assembly 30 has beendrawn through the opening 31 in the bag assembly 30, the bag assembly 30is turned inside-out and enters the expansion chamber 731. The largeraperture areas in the outer concentric patterns 735 draw the outsideedges of the bag assembly 30 towards the side walls of the expansionchamber 731 as the bag assembly 30 moves from the inverting cone 720into the expansion chamber 731. Once the all of the bag assembly 30 hasentered the expansion chamber 731, the vacuum from the manifold chamber732 draws through the apertures 734 in the baffle plate 733 to positionthe bag assembly 30 flat against the baffle plate 733.

[0033] After the bag assembly 30 has been drawn against the baffle plate733, the vacuum in the manifold chamber 732 is discontinued, and theexit door 737 in the expansion box 730 is opened. The ejection jets 740direct pulses of air downward and outward on the bag assembly 30.Because the baffle plate 733 of the expansion box 730 is horizontal, thepulses of air from the ejection jets 740 force the bag assembly 30 outof the expansion chamber 731 through the exit door 737 onto the ramp 735without disturbing the shape of the bag assembly 30.

[0034] The assembled and inverted bag 30 is passed through a metaldetector 810 to insure that there is no metal in the bag assembly 30. Topass the bag assembly 30 through the metal detector 810, a shortconveyor section 820 receives the bag assembly 30 from the ramp 735 ofthe inverting device 700 and passes the bag assembly 30 under the metaldetector 810. In an embodiment where the bag assembly 30 needs lifted tothe level of the detector 810, a lift can be used to bring the detectorconveyor belt 811 and bag assembly 20 to the level of the metal detector810. Alternatively, the detector conveyor belt 811 can be positioned onan incline, with the lower end receiving the bag assembly 30 from theramp 735 of the inverting device 700, and the bag assembly though themetal detector 800.

[0035] The final step is the packing of the bag assemblies incontainers. The bags must be located in alternating positions in thecontainer. Placing the bags in the container at alternating positions ofthe container can be done with a robot, the 3-Way Transfer Device, orsome other automated device.

What is claimed is:
 1. A turning device for a bag comprising: aninverting cone including an inlet separated from an outlet by a length,wherein the cross-sectional area of the inverting cone increases fromthe inlet to the outlet along the length of the inverting cone anexpansion box including an expansion chamber separated from a manifoldchamber by a baffle plate, wherein the baffle plate includes concentriccircles of apertures communicating between the expansion chamber and themanifold chamber, and the outlet of the inverting cone being open to theexpansion chamber opposite to the center of the concentric circles ofapertures in the baffle plate.
 2. The turning device according to claim1, wherein the apertures in the baffle plate of the expansion box arepositioned in concentric circles of apertures.
 3. The turning deviceaccording to claim 2, wherein the concentric circle of apertures arecentered below the outlet of the inverting cone.
 4. The turning deviceaccording to claim 3, wherein the aperture area of each concentriccircle of apertures is larger than the aperture area of the adjacentinner concentric circle of apertures.
 5. The turning device according toclaim 1, wherein the expansion box further includes a door for access tothe expansion chamber.
 6. The turning device according to claim 5,further including ejection jets position for directing air downwardtowards the baffle plate and towards the door.
 7. The turning deviceaccording to claim 6, wherein the ejection jets direct pulses of air.